US20190109446A1 - Seal for electrical box - Google Patents
Seal for electrical box Download PDFInfo
- Publication number
- US20190109446A1 US20190109446A1 US16/211,969 US201816211969A US2019109446A1 US 20190109446 A1 US20190109446 A1 US 20190109446A1 US 201816211969 A US201816211969 A US 201816211969A US 2019109446 A1 US2019109446 A1 US 2019109446A1
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- United States
- Prior art keywords
- electrical box
- seal
- opening
- building structure
- sidewalls
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/12—Distribution boxes; Connection or junction boxes for flush mounting
- H02G3/123—Distribution boxes; Connection or junction boxes for flush mounting in thin walls
- H02G3/126—Distribution boxes; Connection or junction boxes for flush mounting in thin walls with supporting means for mounting on a single wall stud
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/12—Distribution boxes; Connection or junction boxes for flush mounting
- H02G3/123—Distribution boxes; Connection or junction boxes for flush mounting in thin walls
Definitions
- the present invention relates to electrical boxes and flush mounted device boxes such as currently used for mounting electrical devices in walls, floors, and ceilings, and more particularly to an electrical outlet box and flush mounted device box that maintains a vapor barrier about a perimeter thereof.
- Electrical boxes are used in building construction for enclosing electrical components such as switches, outlets, and electrical appliance connections.
- the electrical box is generally secured to studs or joists in a wall, ceiling, or floor construction with an open front or face of the electrical box facing toward an interior of a room.
- a vapor barrier provided by the wall to prevent cold winter air from entering into a structure or building through the wall must be at least partially penetrated by the mounting of the box. Therefore, it is highly desirable to provide a new and improved electrical box, which allows the box to be installed in a wall, while maintaining an integrity of the vapor barrier of the wall.
- One method of providing a vapor barrier in external walls and ceilings of a building is to provide a vapor seal comprising a continuous plastic sheet between the studs and the drywall of the building.
- the vapor seal forms an entirely encompassing vapor barrier around an exterior wall of the building to prevent undesired leakage of air into or out of the building.
- the use of the electrical box requires penetration of the vapor seal, as well as the layers of drywall provided adjacent the vapor seal.
- the electrical box is installed into an existing wall structure wherein components such as the joists, the studs, the vapor seal, and the layers of drywall are already installed. Electrical boxes used for such applications are typically referred to as “old work” electrical boxes.
- the introduction of the new electrical box typically requires portions of the wall or ceiling construction, including the drywall and potentially a portion of the vapor seal, to be penetrated and subsequently removed to form an opening having a shape and size corresponding to a shape and size of a periphery of the electrical box.
- One or more gaps may be created about the periphery of the electrical box if such an opening does not correspond precisely to the shape and size of the periphery of the electrical box.
- air may flow between a space in the wall or the ceiling present outboard of the vapor barrier and an interior of the room requiring the opening, thereby reducing a thermal efficiency of the wall or the ceiling.
- an electrical box comprises a front surface having an opening formed therein providing access to a hollow interior of the electrical box, at least one sidewall extending rearwardly from the front surface to form the hollow interior, and a seal disposed on an exterior surface of the at least one sidewall.
- FIG. 1 is an exploded perspective view of an electrical box and a portion of a building structure having a peripheral seal, the electrical box shown prior to installation of the electrical box into an opening formed in the building structure according to an embodiment of the invention
- FIG. 2 is a cross-sectional elevational view of the electrical box of FIG. 1 prior to installation into the opening of the building structure;
- FIG. 3 is a cross-sectional elevational view of the electrical box of FIG. 1 shown installed in the opening of the building structure;
- FIG. 4 is an enlarged fragmentary cross-sectional elevational view of an electrical box having a modified retention flange according to another embodiment of the invention.
- FIG. 5 is an enlarged fragmentary cross-sectional elevational view of an electrical box having a modified peripheral seal according to another embodiment of the invention.
- FIG. 6 is a top plan view of a peripheral seal having a circular perimeter shape configured for reception on an electrical box having an exterior surface with a circular perimeter shape;
- FIG. 7 is a cross-sectional elevational view of the peripheral seal of FIG. 6 ;
- FIG. 8 is a top plan view of a peripheral seal having an octagonal perimeter shape configured for reception on an electrical box having an exterior surface with an octagonal perimeter shape;
- FIG. 9 is a cross-sectional elevational view of the peripheral seal of FIG. 8 .
- FIGS. 1-3 illustrate an electrical box 10 according to an embodiment of the invention.
- the electrical box 10 may be configured as an “old work” electrical box, meaning that the electrical box 10 may be suitable for installation into a finished wall or ceiling structure having a layer of drywall already installed.
- the electrical box 10 may be adapted for any use consistent with the housing of electrical components therein.
- the electrical box 10 may be an outlet box or a flush mounted device box, for example.
- the electrical box 10 may be provided in several different materials. These include, but are not limited to, steel, other metals, various moldable thermoplastics such as PVC, polycarbonate, polyphenylene oxide, and fiberglass reinforced polyester.
- a single gang rectangular box is shown in FIGS. 1-3 . However, such boxes are also provided in a two gang box, a three gang box, and a four gang box with and without optional mounting brackets, as desired.
- the electrical box 10 is configured for installation in a building structure 80 including at least one layer of drywall 82 and an optional vapor seal 84 disposed adjacent the at least one layer of drywall 82 .
- the building structure 80 is described and illustrated throughout as including a single layer of the drywall 82 having a standard thickness. However, it is understood that the electrical box 10 may be adapted for use with drywall of any thickness or any number of layers of the drywall without departing from the scope of the present invention. It is also understood that the electrical box 10 may be used in conjunction with any type of building material suitable for forming an opening for housing the electrical box 10 , including wood constructions, metal constructions, composite constructions, combinations thereof, and the like.
- the vapor seal 84 may be formed from a layer of plastic or similar material disposed adjacent and oriented substantially parallel with the layer of the drywall 82 to provide a sealing structure for preventing the flow of air therethrough.
- the building structure 80 may further include a plurality of studs (not shown) or joists (not shown) spaced apart from each other and in abutment with one of the vapor seal 84 or the layer of drywall 82 .
- the building structure 80 may include an opening 88 formed therein for receiving the electrical box 10 .
- the opening 88 extends through the layer of drywall 82 as well as the optional vapor seal 84 to allow the electrical box 10 to penetrate the building structure 80 .
- the electrical box 10 is thus received at least partially within a hollow interior of the building structure 80 formed intermediate the layer of drywall 82 and/or vapor seal 84 and an exterior surface (not shown) of the building having the building structure 80 .
- the electrical box 10 includes a plurality of sidewalls 16 forming a closed perimeter of the electrical box 10 .
- the electrical box 10 illustrated in FIGS. 1-3 has a rectangular perimeter shape including a pair of opposing short sides 20 and a pair of opposing long sides 22 .
- An inner or rear wall 14 of the electrical box 10 is formed at one end of the sidewalls 16 and is configured to be disposed beyond an inner surface of the building structure 80 when the electrical box 10 is installed into the opening 88 .
- the inner wall 14 of the electrical box 10 may be substantially closed off with the exception of various openings (not shown) or knockouts (not shown) for receiving electrical components to be received within the electrical box 10 .
- the openings or knockouts may be formed in one of the sidewalls 16 of the electrical box 10 , as desired. In other embodiments, the opening or knockouts may form a portion of a structure for coupling the electrical box to a portion of the building structure 80 such as a joist or stud thereof.
- a front surface 18 of the electrical box 10 is disposed opposite the inner wall 14 thereof.
- the front surface 18 of the electrical box 10 is substantially planar and includes a central opening 19 providing access to a hollow interior 5 of the electrical box 10 delimited by each of the sidewalls 16 and the inner wall 14 thereof.
- the central opening 19 is substantially rectangular in shape and generally corresponds to the rectangular shape formed by the cooperating structure of the sidewalls 16 .
- the front surface 18 of the electrical box 10 further includes a plurality of retention flanges 26 .
- the retention flanges 26 are disposed at each of the corners of the front surface 18 as shown, but any arrangement of the retention flanges 26 may be used without departing from the scope of the present invention. It is understood the retention flanges 26 may be unitary to form a substantially contiguous retention flange around the perimeter of the central opening 19 . Each of the retention flanges 26 forms a projecting portion of the front surface 18 of the electrical box 10 extending outwardly beyond one or more of the sidewalls 16 thereof.
- Each of the retention flanges 26 includes a front surface 35 formed co-planar with the remainder of the front surface 18 of the electrical box 10 and a rear surface 36 spaced from the front surface 18 by a thickness dimension of each of the retention flanges 26 .
- the rear surface 36 of each of the retention flanges 26 is configured to abut an outer surface 86 of the layer of drywall 82 when the electrical box 10 is fully received in the opening 88 formed through the building structure 80 .
- the retention flanges 26 space the remainder of the front surface 18 of the electrical box 10 from the outer surface 86 of the layer of drywall 82 by a distance equal to the thickness dimension of each of the retention flanges 26 .
- the retention flanges 26 provide a stopping mechanism for establishing an axial position of the electrical box 10 within the opening 88 formed in the building structure 80 .
- the electrical box 10 further includes a peripheral edge 27 formed at those portions of the front surface 18 of the electrical box 10 intersecting the sidewalls 16 thereof intermediate adjacent ones of the retention flanges 26 .
- Each portion of the peripheral edge 27 is accordingly disposed co-planar with the remainder of the front surface 18 of the electrical box 10 while also spaced in an axial direction of the electrical box 10 from the rear surface 36 of each of the retention flanges 26 by the thickness dimension of each of the retention flanges 26 .
- the peripheral edge 27 of the electrical box 10 preferably corresponds to the shape of the opening 88 of the building structure 80 at the outer surface 86 of the layer of drywall 82 .
- the opening 88 it is not unusual for the opening 88 to be formed slightly larger than the exterior surface of the electrical box 10 while having inconsistent edges or dimensions following formation of the opening 88 . In some instances, these inconsistent edges are formed as a result of cracking or chipping of a portion of the layer of drywall 82 during the formation of the opening 88 .
- the opening 88 may have an inconsistent shape due to user error during formation of the opening 88 or tools used to form the opening 88 .
- the opening 88 may also be intentionally oversized to ensure entry of the electrical box 10 during installation of the electrical box 10 in the opening 88 .
- the front surface 18 of the electrical box 10 is illustrated as having a pair of clamping apertures 28 .
- the clamping apertures 28 are shown as formed adjacent corners of the front surface 18 , but any suitable position for the clamping apertures 28 may be used without departing from the scope of the present invention.
- Each of the clamping apertures 28 is configured to receive a clamping screw 29 forming a portion of a swing clamp 30 for clamping the electrical box 10 to the building structure 80 .
- the swing clamp 30 includes a clamping arm 32 configured to be drawn towards an end of the clamping screw 29 disposed at the front surface 18 of the electrical box 10 when the clamping screw 29 is rotated within the associated clamping aperture 28 .
- the clamping arm 32 is also rotatable to a position wherein the clamping arm 32 does not extend beyond the peripheral edge 27 of the front surface 18 to allow the electrical box 10 to be received within the opening 88 formed in the layer of drywall 82 without providing interference thereto.
- the clamping arm 32 is then rotatable to be positioned in facing relationship with an inner surface 87 of the layer of drywall 82 disposed outboard of the opening 88 or the optional layer of the vapor seal 84 following the insertion of the electrical box 10 within the opening 88 .
- the electrical box 10 has been described as including a swing clamp 30 for coupling the electrical box 10 to the building structure 80 , it should be understood that the electrical box 10 may be adapted for use with any suitable coupling method for retaining an electrical box within an opening formed as part of an old work electrical box installation.
- the electrical box 10 may be coupled directly to the joists or studs abutting the vapor seal 84 or the layer of drywall 82 . Accordingly, side entry fastening means and the like may be employed for such circumstances, as desired.
- the electrical box 10 may further include a plurality of bosses 55 formed in the front surface 18 thereof. Each of the bosses 55 may form a connection for an electrical device (not shown) to be disposed within the electrical box 10 .
- an electrical device not shown
- alternative methods of connecting an associated electrical device within the electrical box 10 may be used without departing from the scope of the present invention.
- the electrical box 10 includes a peripheral seal 40 disposed on an exterior surface of each of the sidewalls 16 of the electrical box 10 at a position adjacent the front surface 18 thereof.
- the peripheral seal 40 includes a substantially triangular cross-sectional shape including a thick end 41 disposed in alignment with the rear surface 36 of each of the retention flanges 26 and spaced from the peripheral edge 27 of the front surface 18 by the thickness dimension of each of the retention flanges 26 .
- the peripheral seal 40 further includes a thin end 42 spaced from the thick end 41 in the axial direction of the electrical box 10 .
- the phrase “thick end” refers to the end of the peripheral seal 40 having a thickness in a radially outward direction of the electrical box 10 in comparison to the thin end 42 of the electrical box 10 , which is substantially pointed and therefore has substantially no thickness or a very slight thickness.
- the thick end 41 of the peripheral seal 40 may have any desired thickness suitable for ensuring that a space formed between the exterior of the electrical box 10 and an interior surface 95 of the building structure 80 defining the opening 88 thereof.
- the thick end 41 may have a thickness of about 1 ⁇ 8 inch, as a non-limiting example. Other thicknesses for the thick end 41 may be used without departing from the scope of the present invention.
- a spacing between the thin end 42 and the thick end 41 of the peripheral seal 40 is slightly smaller than a thickness of the layer of the drywall 82 forming the building construction 80 .
- the spacing between the thin end 42 and the thick end 41 may be selected to be substantially equal to a combined thickness of the layer or layers of drywall 82 and the optional layer of the vapor seal 84 .
- the spacing between the thin end 42 and the thick end 41 may be equal to the thickness of a single layer of the drywall 82 , a combined thickness of a single layer of the drywall 82 and one layer of the vapor seal 84 , a combined thickness of two layers of drywall 82 , or a combined thickness of two layers of drywall 82 and a single layer of the vapor seal 84 , as non-limiting examples.
- the spacing between the thin end 42 and the thick end 41 is selected to be greater than or less than the combined thickness of each of the layers forming the building structure 80 .
- the triangular cross-sectional shape of the peripheral seal 40 allows for improved entry of the electrical box 10 having the peripheral seal 40 into the opening 88 formed in the building construction 80 .
- the thin end 42 of the peripheral seal 40 has substantially the same size and perimeter shape as that of an exterior surface of the plurality of the sidewalls 16 adjacent the front surface 18 of the electrical box 10 to allow the thin end 42 of the peripheral seal 40 to enter the opening 88 without substantial interference. Assuming the opening 88 is slightly larger than the exterior surface of the plurality of the sidewalls 16 adjacent the front surface 18 to ensure entry thereof, the entry of the peripheral seal 40 into the opening 88 will result in a tapered outer surface 43 of the peripheral seal 40 eventually contacting the inner surface 95 of the layer of drywall 82 defining the opening 88 .
- the peripheral seal 40 is not in a state of compression prior to the insertion of the electrical box 10 into the opening 88 .
- the entry of the peripheral seal 40 into the opening 88 eventually causes compression of the peripheral seal 40 intermediate the surface 95 and the sidewalls 16 of the electrical box 10 .
- the continued compression of the peripheral seal 40 thereby causes a greater percentage of the outer surface 43 of the peripheral seal 40 to engage the inner surface 95 of the layer of drywall 82 .
- FIG. 3 in some circumstances only a portion of the peripheral seal 40 is compressed following complete insertion of the electrical box 10 into the opening 88 .
- the compressed portion of the peripheral seal 40 creates a seal around an entirety of the exterior surface of the plurality of the sidewalls 16 adjacent the front surface 18 of the electrical box 10 to prevent the flow of air from the inner surface 87 of the building structure 80 to the outer surface 86 thereof, and vice versa.
- the peripheral seal 40 may be formed from any suitable material that is substantially fluid impermeable, capable of being compressed, and having suitable insulating properties. Favorable results have been obtained when the peripheral seal is resiliently compressible.
- the peripheral seal 40 may for example be formed from a compressible polymeric material.
- the peripheral seal 40 is formed from a closed cell foam.
- the closed cell foam may be in the form of an adhesive backed strip adhered to the electrical box 10 about the exterior surface of the plurality of the sidewalls 16 adjacent the front surface 18 of the electrical box 10 .
- the adhesive backed strip may include opposing ends that abut each other when the adhesive backed strip is disposed on the sidewalls 16 of the electrical box 10 to fully surround the opening 19 formed in the electrical box 10 .
- the thick end 41 of the peripheral seal 40 may be aligned with the plane defined by the rear surface 36 of each of the retention flanges 26 , thereby causing the thick end 41 to be spaced axially from the peripheral edge 27 by the thickness dimension of each of the retention flanges 26 . If the peripheral seal 40 is formed by the adhesive backed strip, the thick end 41 thereof may abut the rear surface 36 of each of the retention flanges 26 before the adhesive surface of the peripheral seal 40 contacts the exterior surface of each of the sidewalls 16 about the periphery thereof.
- the peripheral seal 40 may be formed from a moldable material molded to the exterior surface of the plurality of the sidewalls 16 adjacent the front surface 18 of the electrical box 10 .
- a mold (not shown) having an interior chamber corresponding in shape and size to the triangular cross-sectional shape of the peripheral seal 40 may be disposed adjacent the sidewalls 16 of the electrical box 10 adjacent the front surface 18 thereof and the moldable material may be injected into the mold. The moldable material may then be cooled and cured to form the peripheral seal 40 on the exterior surface of the plurality of the sidewalls 16 adjacent the front surface 18 of the electrical box 10 .
- FIG. 4 illustrates one alternative configuration of the electrical box 10 and the peripheral seal 40 .
- a retention flange 126 of the electrical box 10 includes a rear surface 136 formed co-planar with the remainder of the front surface 18 of the electrical box 10 and a front surface 135 spaced from the front surface 18 by the thickness dimension of the retention flange 126 .
- This arrangement allows for the thick end 41 of the peripheral seal 40 to be arranged co-planar with the remainder of the front surface 18 of the electrical box 10 .
- This arrangement eliminates the axial spacing between the thick end 41 of the peripheral seal 40 and the front surface 18 of the electrical box 10 .
- FIG. 5 illustrates a peripheral seal 140 according to another embodiment of the invention.
- the peripheral seal 140 includes a rectangular cross-sectional portion 145 and a triangular cross-sectional portion 147 .
- the rectangular cross-sectional portion 145 is configured to be disposed adjacent the front surface 18 of the electrical box 10 while the triangular cross-sectional portion 147 is spaced from the front surface 18 and configured to first enter the opening 88 of the building construction 80 when the electrical box 10 is installed therein.
- the triangular cross-sectional portion 147 includes a tapered surface 148 in similar fashion to the tapered surface 43 of the peripheral seal 40 to allow for ease of entry of the electrical box 10 into the opening 88 .
- peripheral seal 140 allows for the peripheral seal 140 to include a greater axial length thereof compressed to a maximum extent when the electrical box 10 is installed into the opening 88 of the building structure 80 , thereby increasing a sealing effect of the peripheral seal 140 .
- FIGS. 6 and 7 illustrate a peripheral seal 240 having a circular perimeter shape with a triangular cross-sectional shape similar to the cross-sectional shape of the peripheral seal 40 .
- FIGS. 8 and 9 illustrate a peripheral seal 340 having an octagonal perimeter shape with a triangular cross-sectional shape similar to the triangular cross-sectional shape of the peripheral seal 40 .
- peripheral seals 240 , 340 may alternatively be formed to include both a triangular cross-sectional portion and a rectangular cross-sectional portion in similar fashion to the peripheral seal 140 , as desired, without departing from the scope of the present invention.
- an electrical box utilizing any one of the peripheral seals 40 , 140 , 240 , 340 shown and described herein provides numerous benefits over an electrical box devoid of such a peripheral seal.
- the triangular cross-sectional shape of the peripheral seal facilitates an ease of entry of the electrical box into the corresponding opening of the building structure due to the initial entry of the pointed end thereof.
- the eventual compression of the peripheral seal during the axial entry of the electrical box partially secures the axial position of the electrical box relative to the opening of the building structure to prevent undesired movement of the electrical box when attempting to secure the electrical box to the building structure.
- the presence of the peripheral seal prevents the flow of air around the exterior surface of the electrical box, thereby improving the vapor barrier formed by the building structure having the electrical box installed therein.
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Abstract
Description
- This patent application is a continuation patent application of U.S. patent application Ser. No. 15/795,435 filed Oct. 27, 2017, which claims priority to U.S. Provisional Patent Application Ser. No. 62/414,141 filed on Oct. 28, 2016, the entire disclosures of which are hereby incorporated herein by reference.
- The present invention relates to electrical boxes and flush mounted device boxes such as currently used for mounting electrical devices in walls, floors, and ceilings, and more particularly to an electrical outlet box and flush mounted device box that maintains a vapor barrier about a perimeter thereof.
- Electrical boxes are used in building construction for enclosing electrical components such as switches, outlets, and electrical appliance connections. The electrical box is generally secured to studs or joists in a wall, ceiling, or floor construction with an open front or face of the electrical box facing toward an interior of a room. When an electrical box is utilized, a vapor barrier provided by the wall to prevent cold winter air from entering into a structure or building through the wall must be at least partially penetrated by the mounting of the box. Therefore, it is highly desirable to provide a new and improved electrical box, which allows the box to be installed in a wall, while maintaining an integrity of the vapor barrier of the wall.
- One method of providing a vapor barrier in external walls and ceilings of a building is to provide a vapor seal comprising a continuous plastic sheet between the studs and the drywall of the building. The vapor seal forms an entirely encompassing vapor barrier around an exterior wall of the building to prevent undesired leakage of air into or out of the building. The use of the electrical box requires penetration of the vapor seal, as well as the layers of drywall provided adjacent the vapor seal. Heretofore, it is extremely difficult to provide a vapor seal between the electrical box and the drywall to maintain the integrity of the vapor barrier. Therefore, it is highly desirable to provide a new and improved electrical box that can provide the vapor seal at the vapor barrier of the exterior wall or the ceiling to maintain the integrity of the vapor barrier.
- In many circumstances, the electrical box is installed into an existing wall structure wherein components such as the joists, the studs, the vapor seal, and the layers of drywall are already installed. Electrical boxes used for such applications are typically referred to as “old work” electrical boxes. The introduction of the new electrical box typically requires portions of the wall or ceiling construction, including the drywall and potentially a portion of the vapor seal, to be penetrated and subsequently removed to form an opening having a shape and size corresponding to a shape and size of a periphery of the electrical box. One or more gaps may be created about the periphery of the electrical box if such an opening does not correspond precisely to the shape and size of the periphery of the electrical box. Thus, air may flow between a space in the wall or the ceiling present outboard of the vapor barrier and an interior of the room requiring the opening, thereby reducing a thermal efficiency of the wall or the ceiling.
- It is desirable to provide a new and improved electrical box that not only can be mounted in a manner to maintain the integrity of a vapor barrier in an exterior wall or ceiling of a building, but which also accommodates any small inconsistencies in dimensions, alignment, and the like of the electrical box within the wall structure, allowing fast and efficient construction, while at the same time maintaining a vapor seal about a periphery of the electrical box.
- In concordance and agreement with the present invention, an electrical box providing a seal about a perimeter of an exterior surface thereof has surprisingly been discovered.
- In one embodiment, an electrical box comprises a front surface having an opening formed therein providing access to a hollow interior of the electrical box, at least one sidewall extending rearwardly from the front surface to form the hollow interior, and a seal disposed on an exterior surface of the at least one sidewall.
- The above objects and advantages of the invention, as well as others, will become readily apparent to those skilled in the art from reading the following detailed description of a preferred embodiment of the invention when considered in the light of the accompanying drawings, in which:
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FIG. 1 is an exploded perspective view of an electrical box and a portion of a building structure having a peripheral seal, the electrical box shown prior to installation of the electrical box into an opening formed in the building structure according to an embodiment of the invention; -
FIG. 2 is a cross-sectional elevational view of the electrical box ofFIG. 1 prior to installation into the opening of the building structure; -
FIG. 3 is a cross-sectional elevational view of the electrical box ofFIG. 1 shown installed in the opening of the building structure; -
FIG. 4 is an enlarged fragmentary cross-sectional elevational view of an electrical box having a modified retention flange according to another embodiment of the invention; -
FIG. 5 is an enlarged fragmentary cross-sectional elevational view of an electrical box having a modified peripheral seal according to another embodiment of the invention; -
FIG. 6 is a top plan view of a peripheral seal having a circular perimeter shape configured for reception on an electrical box having an exterior surface with a circular perimeter shape; -
FIG. 7 is a cross-sectional elevational view of the peripheral seal ofFIG. 6 ; -
FIG. 8 is a top plan view of a peripheral seal having an octagonal perimeter shape configured for reception on an electrical box having an exterior surface with an octagonal perimeter shape; and -
FIG. 9 is a cross-sectional elevational view of the peripheral seal ofFIG. 8 . - The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.
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FIGS. 1-3 illustrate anelectrical box 10 according to an embodiment of the invention. Theelectrical box 10 may be configured as an “old work” electrical box, meaning that theelectrical box 10 may be suitable for installation into a finished wall or ceiling structure having a layer of drywall already installed. Theelectrical box 10 may be adapted for any use consistent with the housing of electrical components therein. Theelectrical box 10 may be an outlet box or a flush mounted device box, for example. Theelectrical box 10 may be provided in several different materials. These include, but are not limited to, steel, other metals, various moldable thermoplastics such as PVC, polycarbonate, polyphenylene oxide, and fiberglass reinforced polyester. A single gang rectangular box is shown inFIGS. 1-3 . However, such boxes are also provided in a two gang box, a three gang box, and a four gang box with and without optional mounting brackets, as desired. - As shown in
FIG. 1 , theelectrical box 10 is configured for installation in abuilding structure 80 including at least one layer ofdrywall 82 and anoptional vapor seal 84 disposed adjacent the at least one layer ofdrywall 82. Thebuilding structure 80 is described and illustrated throughout as including a single layer of thedrywall 82 having a standard thickness. However, it is understood that theelectrical box 10 may be adapted for use with drywall of any thickness or any number of layers of the drywall without departing from the scope of the present invention. It is also understood that theelectrical box 10 may be used in conjunction with any type of building material suitable for forming an opening for housing theelectrical box 10, including wood constructions, metal constructions, composite constructions, combinations thereof, and the like. - The
vapor seal 84 may be formed from a layer of plastic or similar material disposed adjacent and oriented substantially parallel with the layer of thedrywall 82 to provide a sealing structure for preventing the flow of air therethrough. Thebuilding structure 80 may further include a plurality of studs (not shown) or joists (not shown) spaced apart from each other and in abutment with one of thevapor seal 84 or the layer ofdrywall 82. - The
building structure 80 may include an opening 88 formed therein for receiving theelectrical box 10. Theopening 88 extends through the layer ofdrywall 82 as well as theoptional vapor seal 84 to allow theelectrical box 10 to penetrate thebuilding structure 80. Theelectrical box 10 is thus received at least partially within a hollow interior of thebuilding structure 80 formed intermediate the layer ofdrywall 82 and/orvapor seal 84 and an exterior surface (not shown) of the building having thebuilding structure 80. - The
electrical box 10 includes a plurality of sidewalls 16 forming a closed perimeter of theelectrical box 10. Theelectrical box 10 illustrated inFIGS. 1-3 has a rectangular perimeter shape including a pair of opposing short sides 20 and a pair of opposing long sides 22. An inner orrear wall 14 of theelectrical box 10 is formed at one end of the sidewalls 16 and is configured to be disposed beyond an inner surface of thebuilding structure 80 when theelectrical box 10 is installed into theopening 88. Theinner wall 14 of theelectrical box 10 may be substantially closed off with the exception of various openings (not shown) or knockouts (not shown) for receiving electrical components to be received within theelectrical box 10. In some embodiments, the openings or knockouts may be formed in one of the sidewalls 16 of theelectrical box 10, as desired. In other embodiments, the opening or knockouts may form a portion of a structure for coupling the electrical box to a portion of thebuilding structure 80 such as a joist or stud thereof. - A
front surface 18 of theelectrical box 10 is disposed opposite theinner wall 14 thereof. Thefront surface 18 of theelectrical box 10 is substantially planar and includes acentral opening 19 providing access to ahollow interior 5 of theelectrical box 10 delimited by each of the sidewalls 16 and theinner wall 14 thereof. Thecentral opening 19 is substantially rectangular in shape and generally corresponds to the rectangular shape formed by the cooperating structure of the sidewalls 16. - In the embodiment shown, the
front surface 18 of theelectrical box 10 further includes a plurality ofretention flanges 26. The retention flanges 26 are disposed at each of the corners of thefront surface 18 as shown, but any arrangement of theretention flanges 26 may be used without departing from the scope of the present invention. It is understood theretention flanges 26 may be unitary to form a substantially contiguous retention flange around the perimeter of thecentral opening 19. Each of theretention flanges 26 forms a projecting portion of thefront surface 18 of theelectrical box 10 extending outwardly beyond one or more of the sidewalls 16 thereof. Each of theretention flanges 26 includes afront surface 35 formed co-planar with the remainder of thefront surface 18 of theelectrical box 10 and arear surface 36 spaced from thefront surface 18 by a thickness dimension of each of theretention flanges 26. Therear surface 36 of each of theretention flanges 26 is configured to abut anouter surface 86 of the layer ofdrywall 82 when theelectrical box 10 is fully received in theopening 88 formed through thebuilding structure 80. The retention flanges 26 space the remainder of thefront surface 18 of theelectrical box 10 from theouter surface 86 of the layer ofdrywall 82 by a distance equal to the thickness dimension of each of theretention flanges 26. The retention flanges 26 provide a stopping mechanism for establishing an axial position of theelectrical box 10 within theopening 88 formed in thebuilding structure 80. - The
electrical box 10 further includes aperipheral edge 27 formed at those portions of thefront surface 18 of theelectrical box 10 intersecting the sidewalls 16 thereof intermediate adjacent ones of theretention flanges 26. Each portion of theperipheral edge 27 is accordingly disposed co-planar with the remainder of thefront surface 18 of theelectrical box 10 while also spaced in an axial direction of theelectrical box 10 from therear surface 36 of each of theretention flanges 26 by the thickness dimension of each of theretention flanges 26. - The
peripheral edge 27 of theelectrical box 10 preferably corresponds to the shape of theopening 88 of thebuilding structure 80 at theouter surface 86 of the layer ofdrywall 82. However, as explained hereinafter, it is not unusual for theopening 88 to be formed slightly larger than the exterior surface of theelectrical box 10 while having inconsistent edges or dimensions following formation of theopening 88. In some instances, these inconsistent edges are formed as a result of cracking or chipping of a portion of the layer ofdrywall 82 during the formation of theopening 88. Alternatively, theopening 88 may have an inconsistent shape due to user error during formation of theopening 88 or tools used to form theopening 88. Theopening 88 may also be intentionally oversized to ensure entry of theelectrical box 10 during installation of theelectrical box 10 in theopening 88. - The
front surface 18 of theelectrical box 10 is illustrated as having a pair of clampingapertures 28. The clampingapertures 28 are shown as formed adjacent corners of thefront surface 18, but any suitable position for the clampingapertures 28 may be used without departing from the scope of the present invention. Each of the clampingapertures 28 is configured to receive a clampingscrew 29 forming a portion of aswing clamp 30 for clamping theelectrical box 10 to thebuilding structure 80. - The
swing clamp 30 includes a clampingarm 32 configured to be drawn towards an end of the clampingscrew 29 disposed at thefront surface 18 of theelectrical box 10 when the clampingscrew 29 is rotated within the associated clampingaperture 28. The clampingarm 32 is also rotatable to a position wherein the clampingarm 32 does not extend beyond theperipheral edge 27 of thefront surface 18 to allow theelectrical box 10 to be received within theopening 88 formed in the layer ofdrywall 82 without providing interference thereto. The clampingarm 32 is then rotatable to be positioned in facing relationship with aninner surface 87 of the layer ofdrywall 82 disposed outboard of theopening 88 or the optional layer of thevapor seal 84 following the insertion of theelectrical box 10 within theopening 88. Rotation of the clampingscrew 29 within the clampingaperture 28 draws the clampingarm 32 towards thefront surface 18 of theelectrical box 10. The layer ofdrywall 82 and the optional layer of thevapor seal 84 are eventually sandwiched between therear surface 36 of each of theretention flanges 26 and the clampingarm 32 of each of the swing clamps 30. Theswing clamp 30 accordingly aids in securing an axial position of theelectrical box 10 in theopening 88 of thebuilding structure 80. - Although the
electrical box 10 has been described as including aswing clamp 30 for coupling theelectrical box 10 to thebuilding structure 80, it should be understood that theelectrical box 10 may be adapted for use with any suitable coupling method for retaining an electrical box within an opening formed as part of an old work electrical box installation. In some circumstances, theelectrical box 10 may be coupled directly to the joists or studs abutting thevapor seal 84 or the layer ofdrywall 82. Accordingly, side entry fastening means and the like may be employed for such circumstances, as desired. - The
electrical box 10 may further include a plurality ofbosses 55 formed in thefront surface 18 thereof. Each of thebosses 55 may form a connection for an electrical device (not shown) to be disposed within theelectrical box 10. However, alternative methods of connecting an associated electrical device within theelectrical box 10 may be used without departing from the scope of the present invention. - The
electrical box 10 includes aperipheral seal 40 disposed on an exterior surface of each of the sidewalls 16 of theelectrical box 10 at a position adjacent thefront surface 18 thereof. Theperipheral seal 40 includes a substantially triangular cross-sectional shape including athick end 41 disposed in alignment with therear surface 36 of each of theretention flanges 26 and spaced from theperipheral edge 27 of thefront surface 18 by the thickness dimension of each of theretention flanges 26. Theperipheral seal 40 further includes athin end 42 spaced from thethick end 41 in the axial direction of theelectrical box 10. As used hereinafter, the phrase “thick end” refers to the end of theperipheral seal 40 having a thickness in a radially outward direction of theelectrical box 10 in comparison to thethin end 42 of theelectrical box 10, which is substantially pointed and therefore has substantially no thickness or a very slight thickness. Thethick end 41 of theperipheral seal 40 may have any desired thickness suitable for ensuring that a space formed between the exterior of theelectrical box 10 and aninterior surface 95 of thebuilding structure 80 defining theopening 88 thereof. Thethick end 41 may have a thickness of about ⅛ inch, as a non-limiting example. Other thicknesses for thethick end 41 may be used without departing from the scope of the present invention. - As shown in
FIGS. 2 and 3 , a spacing between thethin end 42 and thethick end 41 of theperipheral seal 40 is slightly smaller than a thickness of the layer of thedrywall 82 forming thebuilding construction 80. Alternatively, the spacing between thethin end 42 and thethick end 41 may be selected to be substantially equal to a combined thickness of the layer or layers ofdrywall 82 and the optional layer of thevapor seal 84. For example, the spacing between thethin end 42 and thethick end 41 may be equal to the thickness of a single layer of thedrywall 82, a combined thickness of a single layer of thedrywall 82 and one layer of thevapor seal 84, a combined thickness of two layers ofdrywall 82, or a combined thickness of two layers ofdrywall 82 and a single layer of thevapor seal 84, as non-limiting examples. In other embodiments, the spacing between thethin end 42 and thethick end 41 is selected to be greater than or less than the combined thickness of each of the layers forming thebuilding structure 80. - The triangular cross-sectional shape of the
peripheral seal 40 allows for improved entry of theelectrical box 10 having theperipheral seal 40 into theopening 88 formed in thebuilding construction 80. Thethin end 42 of theperipheral seal 40 has substantially the same size and perimeter shape as that of an exterior surface of the plurality of the sidewalls 16 adjacent thefront surface 18 of theelectrical box 10 to allow thethin end 42 of theperipheral seal 40 to enter theopening 88 without substantial interference. Assuming theopening 88 is slightly larger than the exterior surface of the plurality of the sidewalls 16 adjacent thefront surface 18 to ensure entry thereof, the entry of theperipheral seal 40 into theopening 88 will result in a taperedouter surface 43 of theperipheral seal 40 eventually contacting theinner surface 95 of the layer ofdrywall 82 defining theopening 88. As shown inFIG. 2 , theperipheral seal 40 is not in a state of compression prior to the insertion of theelectrical box 10 into theopening 88. As shown inFIG. 3 , the entry of theperipheral seal 40 into theopening 88 eventually causes compression of theperipheral seal 40 intermediate thesurface 95 and the sidewalls 16 of theelectrical box 10. The continued compression of theperipheral seal 40 thereby causes a greater percentage of theouter surface 43 of theperipheral seal 40 to engage theinner surface 95 of the layer ofdrywall 82. As shown inFIG. 3 , in some circumstances only a portion of theperipheral seal 40 is compressed following complete insertion of theelectrical box 10 into theopening 88. The compressed portion of theperipheral seal 40 creates a seal around an entirety of the exterior surface of the plurality of the sidewalls 16 adjacent thefront surface 18 of theelectrical box 10 to prevent the flow of air from theinner surface 87 of thebuilding structure 80 to theouter surface 86 thereof, and vice versa. - The
peripheral seal 40 may be formed from any suitable material that is substantially fluid impermeable, capable of being compressed, and having suitable insulating properties. Favorable results have been obtained when the peripheral seal is resiliently compressible. Theperipheral seal 40 may for example be formed from a compressible polymeric material. In one embodiment, theperipheral seal 40 is formed from a closed cell foam. The closed cell foam may be in the form of an adhesive backed strip adhered to theelectrical box 10 about the exterior surface of the plurality of the sidewalls 16 adjacent thefront surface 18 of theelectrical box 10. The adhesive backed strip may include opposing ends that abut each other when the adhesive backed strip is disposed on the sidewalls 16 of theelectrical box 10 to fully surround theopening 19 formed in theelectrical box 10. - As shown in
FIGS. 1-3 , thethick end 41 of theperipheral seal 40 may be aligned with the plane defined by therear surface 36 of each of theretention flanges 26, thereby causing thethick end 41 to be spaced axially from theperipheral edge 27 by the thickness dimension of each of theretention flanges 26. If theperipheral seal 40 is formed by the adhesive backed strip, thethick end 41 thereof may abut therear surface 36 of each of theretention flanges 26 before the adhesive surface of theperipheral seal 40 contacts the exterior surface of each of the sidewalls 16 about the periphery thereof. - Alternatively, the
peripheral seal 40 may be formed from a moldable material molded to the exterior surface of the plurality of the sidewalls 16 adjacent thefront surface 18 of theelectrical box 10. For example, a mold (not shown) having an interior chamber corresponding in shape and size to the triangular cross-sectional shape of theperipheral seal 40 may be disposed adjacent the sidewalls 16 of theelectrical box 10 adjacent thefront surface 18 thereof and the moldable material may be injected into the mold. The moldable material may then be cooled and cured to form theperipheral seal 40 on the exterior surface of the plurality of the sidewalls 16 adjacent thefront surface 18 of theelectrical box 10. -
FIG. 4 illustrates one alternative configuration of theelectrical box 10 and theperipheral seal 40. In contrast to the embodiment shown inFIGS. 1-3 , aretention flange 126 of theelectrical box 10 includes arear surface 136 formed co-planar with the remainder of thefront surface 18 of theelectrical box 10 and afront surface 135 spaced from thefront surface 18 by the thickness dimension of theretention flange 126. This arrangement allows for thethick end 41 of theperipheral seal 40 to be arranged co-planar with the remainder of thefront surface 18 of theelectrical box 10. This arrangement eliminates the axial spacing between thethick end 41 of theperipheral seal 40 and thefront surface 18 of theelectrical box 10. -
FIG. 5 illustrates aperipheral seal 140 according to another embodiment of the invention. Theperipheral seal 140 includes a rectangularcross-sectional portion 145 and a triangularcross-sectional portion 147. The rectangularcross-sectional portion 145 is configured to be disposed adjacent thefront surface 18 of theelectrical box 10 while the triangularcross-sectional portion 147 is spaced from thefront surface 18 and configured to first enter theopening 88 of thebuilding construction 80 when theelectrical box 10 is installed therein. The triangularcross-sectional portion 147 includes atapered surface 148 in similar fashion to the taperedsurface 43 of theperipheral seal 40 to allow for ease of entry of theelectrical box 10 into theopening 88. The inclusion of the rectangularcross-sectional portion 145 allows for theperipheral seal 140 to include a greater axial length thereof compressed to a maximum extent when theelectrical box 10 is installed into theopening 88 of thebuilding structure 80, thereby increasing a sealing effect of theperipheral seal 140. - The
peripheral seal 40 or theperipheral seal 140 may be adapted for use with electrical boxes having any suitable perimeter shape and size, as desired. For example,FIGS. 6 and 7 illustrate aperipheral seal 240 having a circular perimeter shape with a triangular cross-sectional shape similar to the cross-sectional shape of theperipheral seal 40. Alternatively,FIGS. 8 and 9 illustrate aperipheral seal 340 having an octagonal perimeter shape with a triangular cross-sectional shape similar to the triangular cross-sectional shape of theperipheral seal 40. It is understood that theperipheral seals peripheral seal 140, as desired, without departing from the scope of the present invention. - An electrical box utilizing any one of the
peripheral seals - From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.
Claims (10)
Priority Applications (1)
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US16/211,969 US10447020B2 (en) | 2016-10-28 | 2018-12-06 | Seal for electrical box |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US201662414141P | 2016-10-28 | 2016-10-28 | |
US15/795,435 US10186852B2 (en) | 2016-10-28 | 2017-10-27 | Seal for electrical box |
US16/211,969 US10447020B2 (en) | 2016-10-28 | 2018-12-06 | Seal for electrical box |
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US15/795,435 Continuation US10186852B2 (en) | 2016-10-28 | 2017-10-27 | Seal for electrical box |
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US20190109446A1 true US20190109446A1 (en) | 2019-04-11 |
US10447020B2 US10447020B2 (en) | 2019-10-15 |
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US15/795,435 Active US10186852B2 (en) | 2016-10-28 | 2017-10-27 | Seal for electrical box |
US16/163,732 Active US10483741B2 (en) | 2016-10-28 | 2018-10-18 | Seal for electrical box |
US16/211,969 Active US10447020B2 (en) | 2016-10-28 | 2018-12-06 | Seal for electrical box |
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US15/795,435 Active US10186852B2 (en) | 2016-10-28 | 2017-10-27 | Seal for electrical box |
US16/163,732 Active US10483741B2 (en) | 2016-10-28 | 2018-10-18 | Seal for electrical box |
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Families Citing this family (8)
Publication number | Priority date | Publication date | Assignee | Title |
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US11303105B2 (en) * | 2018-02-27 | 2022-04-12 | Izo Box, Inc. | Insulating box and method for electrical outlets, switches and light fixtures |
US11050229B2 (en) * | 2018-07-16 | 2021-06-29 | Allied Moulded Products, Inc. | Vapor seal with angled flange |
USD886746S1 (en) * | 2018-09-14 | 2020-06-09 | Hogar Controls, Inc. | Modular housing for touch switch |
DE102020203792A1 (en) | 2020-03-24 | 2021-09-30 | Hansgrohe Se | In-wall connection box unit |
DE102020203797A1 (en) * | 2020-03-24 | 2021-09-30 | Hansgrohe Se | In-wall connection box unit with extension sleeve |
DE102020203794A1 (en) | 2020-03-24 | 2021-09-30 | Hansgrohe Se | In-wall connection box unit with functional surface body |
DE102020203800A1 (en) | 2020-03-24 | 2021-09-30 | Hansgrohe Se | Sanitary in-wall connection box unit with electrical cable feed-through |
US11646558B2 (en) * | 2021-10-04 | 2023-05-09 | George Emmanuel Mon | Air sealing electrical box |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
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US4794207A (en) * | 1986-03-21 | 1988-12-27 | Enercept, Inc. | Electrical outlet unit for a building |
CA1305778C (en) * | 1988-08-23 | 1992-07-28 | Glen Rye | Outlet box |
US6239365B1 (en) * | 1999-05-20 | 2001-05-29 | Mcevers Douglas W. | Sealable electrical outlet enclosure |
US6908003B2 (en) | 2000-11-22 | 2005-06-21 | Allied Moulded Products, Inc. | Air tight electrical box |
US6737576B1 (en) * | 2003-05-16 | 2004-05-18 | Thomas & Betts International, Inc. | Electrical box assembly |
US20050178079A1 (en) * | 2004-02-13 | 2005-08-18 | Hardman Barry G. | Modular insert fenestration system |
US7851703B2 (en) * | 2007-09-26 | 2010-12-14 | Thomas & Betts International, Inc. | Gasket sealing and installation process for door gasket on weatherproof outlet electrical box |
US9018524B2 (en) * | 2012-04-10 | 2015-04-28 | Thomas & Betts International, Inc. | Blade-edge vapor-tight electrical box |
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- 2017-10-27 US US15/795,435 patent/US10186852B2/en active Active
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- 2018-10-18 US US16/163,732 patent/US10483741B2/en active Active
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US10483741B2 (en) | 2019-11-19 |
US20190052069A1 (en) | 2019-02-14 |
US10186852B2 (en) | 2019-01-22 |
US20180123332A1 (en) | 2018-05-03 |
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